The whole aluminum profile extrusion process, especially the welding stages, for an upside beam on the train, was simulated by using FEM (Finite Element Method) combined with a mesh reconstruction technology in the welding zone. According to the simulation results, the deformation of the extrudate head, the velocity distribution on the cross-section of the extrudate at the die exit and the pressure in the welding-chamber were analyzed. The die structure was optimized to avoid the phenomena of ‘die blocked’ and bad weld quality. By modifying the structures of the second welding-chamber, the bearing length and baffle block height, the velocity uniformity at the die exit was improved and as a result, the phenomena of ‘die blocked’ was avoided. By modifying the port-bridge structure, the welding-chamber pressure was improved, and consequently, the welding quality was improved.
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